Hinge and support system for an intermediate deck in a trailer

ABSTRACT

A hinge and support system for supporting cargo in a freight compartment is provided. The system includes a hinge member, associated with a deck panel, which has at least one flexible projection. The hinge member mates with a support member having a pocket for which the hinge member&#39;s flexible projections can be snapped into and retained within so as to allow pivotal movement of the hinge member with respect to the support member. The hinge member is also movably supported by the deck panel so that the hinge member can move relative to the deck panel when the deck panel is deployed. The support member includes one ledge which engages the deck panel when deployed and a second ledge which engages the panel when stowed upright so as to substantially isolate the hinge member from the weight of the deck panel and items placed on it. The hinge structure can be utilized in other contexts.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.10/353,266, filed Jan. 29, 2003, now U.S. Pat. No 6,854,400 which ishereby incorporated herein in its entirety by reference, and claims thebenefit of U.S. Provisional Application No. 60/382,660, filed May 21,2002.

FIELD OF THE INVENTION

The invention relates to intermediate deck structures for use intransport vehicles such as trucks and trailer vans, railway cars,freight containers and the like, and more particularly, to a hinge andsupport system for an interlocking deck for use in such vehiclessuitable for loading and transporting parcels.

BACKGROUND OF THE INVENTION

In a typical truck van, a horizontal bed or floor is provided forsupporting articles being transported. Articles are placed on this bed,and depending upon the size of the articles, they may be stacked uponeach other at two or more levels.

In some instances, it may be impractical to stack the articles due tothe weight or configuration. Where this is the case, a substantialamount of the vehicle interior is rendered unusable. For example, wherethe articles or containers are fragile, damage to the articles willoccur if stacked to the extent that the weight of the upper articleswould damage lower articles. In those instances, it is often necessaryto avoid stacking or to minimize the amount of stacking.

Some articles are also somewhat difficult to handle due to their weightand configuration. This creates problems for the individuals loading thearticles on a bed. Thus, even if articles at a lower level will not bedamaged when other articles are stacked thereon, stacking itself may bequite cumbersome and inefficient due to the size and weight of thearticles.

Attempts have been made to address some of these problems byincorporating intermediate decks in vehicles. Various types ofcollapsible or removable intermediate deck structures have been proposedfor supporting freight articles of various shapes and weights above thehorizontal bed or floor of a transport van, and the like, in order toincrease the load carrying ability of a van and to maximize the use ofthe available cubic capacity of a van. The use of collapsible orremovable intermediate decks has not met with wide success, however, dueto inefficiencies in the design of the decks which make them toocomplex, too expensive for practical purposes or simply too inconvenientto use.

The design of existing intermediate deck structures often consist of twodeck panels, hinge mounted on opposing walls to enable storage of thedeck panels vertically against the side walls. The deck panels rotatedownwardly or upwardly on the hinges to a horizontal position to form acontinuous section of deck, or secondary floor. Typically, this formrequires a means of supporting the deck halves horizontally in a mannerwhich both encroaches on additional usable volume for loading thefreight or cargo, and interferes with that space requiring extra effortand time to load around it. Such supports include cantilever supportstructures, suspension chains or cables or even vertical support legsextending to the primary floor.

For example, U.S. Pat. No. 3,911,832 to Vandergriff discloses anintermediate deck structure for use in railway cars, truck and trailervans. The deck structure includes a first section pivotally connected atits outer end to the side wall of a vehicle, and adapted to be pivotedbetween a stored position adjacent the side wall and a horizontalposition with its inner end extending inwardly from the side wall. Asecond section of the Vandergriff intermediate deck has a pair of armsextended from its inner end which are pivotally connected to the firstsection at a point between the inner and outer ends. The second sectionof the intermediate deck is adapted to be stored adjacent the side wallof the vehicle below the first section of the intermediate deck in aposition extending downwardly from the outer end of the stored firstsection. The second section is adapted to be pivoted relative to thefirst section during pivoting of the first section to a horizontalloading position, whereby the second section can also be moved to ahorizontal loading position with the outer end of the second sectionsupported by a pair of load brackets engaged with a load rail on theopposite side wall of the vehicle.

A problem encountered with the intermediate deck structure ofVandergriff is that the individual deck structures do not lock togetherwhen the two deck sections are stored against the side wall of thevehicle, and the load bracket on the second section extends downwardlyto a position where it can interfere with and damage cargo and boxessitting on the main floor of the vehicle. A further problem with theVandergriff deck is that the load brackets employed in the intermediatedeck structure are subject to jumping out of the wall load track railslots, causing the load brackets to retract under a load on the deck,and dropping the load onto the cargo positioned underneath theintermediate deck.

U.S. Pat. No. 5,452,972 to Adams discloses a deck structure for use insupporting cargo at an intermediate level above the floor or bed of atrailer van. The Adams intermediate deck includes a first deck sectionpivotally mounted on a side wall of a trailer van and movable to ahorizontal load position, and back up to a vertical stored positionagainst the side wall. Adams employs a complex spring slam bolt andrelease chain system engaged with a height saving angle locking rail toreleaseably hold the deck section. A second section of the deck ispivotally connected to the first section and it is also movable betweena horizontal load position and a vertical stored position against theside wall. When the second section is in the vertical stored position itis hanging from the first section and is configured such that it nestsin the first deck section to provide a storing intermediate deckstructure. When the first and second deck sections are in a horizontalload position, the second section has an outer end which is selectivelyprovided with either the spring biased, telescopically mounted loadbracket, or a cap style load bracket, that is operatively seated on aload track rail on the trailer van wall opposite to the wall on whichthe first deck section is hinged. Although the intermediate deckstructure of Adams addresses some of the problems of Vandergriff, indoing so it employs complex chain and spring systems that increase theexpense of the intermediate deck structure and enhance the risk ofinjury to the operator of the system. Also, like Vandergriff, Adamsfails to address the problem of the lack of structure to lock individualdeck structures together.

U.S. Pat. No. 3,875,871 to Thorton discloses a freight carrier such as arailroad car having sections which, unlike the structures in Vandergriffor Adams, fold from opposite walls toward one another from a storedposition to an operational position. In the installed position thesections provide a supplementary cargo level. According to Thorton, inthis position the sections have joining means which self-support theload and transmit lading shearing and bending moments between thesections so that additional supports from the floor are not required.The deck sections of the Thorton carrier are provided with flanges orblocks for supporting the sections when they are unfolded and forproviding a resting space for subsequently lowered sections. Thortonalso describes permanent support areas positioned at one end of thefreight car designed to provide a resting area for the first loweredpanels. The patent describes these rest areas as a bracket or ledgemounted on the rear wall of the carrier by suitable fasteners orwelding.

Other U.S. patents showing related structures include U.S. Pat. Nos.4,281,870; 3,897,971; and 5,375,534.

Although Thorton seemingly overcomes many of the problems of Vandergriffand the complexities of Adams, it requires welding structures orfasteners to the interior portion of the carrier to do so. Moreover,although Thorton provides flanges or blocks for supporting subsequentsections, the panels described in Thorton are vulnerable to sag underheavier loads due to inadequate support. Moreover, the flanges or blocksof Thorton subject the panels to interference with one another and, likeVandergriff and Adams, do not interlock the panels together in theoperational position. Another problem encountered with such systems isstress placed on attachment and hinge systems by flexing of trailer sidewalls, for example while the vehicle is travelling on the road.Furthermore, in some systems a hinge utilized for deploying and stowingan intermediate deck may have to bear the full weight of the itemsloaded on the intermediate deck.

Consequently, there is a need for a system for supporting articles moreefficiently for transportation purposes. In particular, there is a needfor such a support system that is of a highly efficient design wherebythe deck can be economically installed in a vehicle, each individualintermediate deck can be adequately supported and locked together withother intermediate decks, the deck system is not adversely affected byflexing of trailer walls, and the system can be efficiently operated bya single user.

SUMMARY OF THE INVENTION

These and other objects and advantages are met by the present inventionwhich includes a deck support system for supporting cargo in a freightcompartment having spaced apart side walls.

One aspect of the present invention is a hinge and support system bywhich a deployable deck panel unit is attached to a side wall of afreight compartment. The freight compartment may be in a vehicle, suchas a semi-trailer, a container of the type used in intermodal shipmentof goods, or other compartment or enclosure suitable for transportingitems. The hinge and support system includes a support member attachedto a side wall of the compartment, the support member defining one ormore pockets opening generally away from the side wall. A hinge memberassociated with a deck panel includes one or more projections shaped tobe inserted into and retained within a mating pocket of the supportmember until selectively removed from the mating pocket. In oneembodiment, the projections are flexible and are inserted and retainedby applying a sufficient force to snap the projections into the pocket.Likewise, the projections can be removed by snapping them out of thepocket. In another embodiment, the hinge member includes rigidprojections that may include a locking plunger and the assembly issnapped into and retained within the mating pocket. In still anotherembodiment, the rigid projections are shaped to allow insertion andremoval only in a particular orientation, but without a snapping actionor application of force. As will become apparent from the detaileddescription below, the shape of the pockets and projections may varywidely so long as they function as described above.

Generally described, this aspect of the invention provides a hinge andsupport system for pivotally mounting a deck panel to a side wall of afreight compartment, comprising: a support member, extending generallyhorizontally along one of the side walls, defining one or more pocketstherein, the one or more pockets each defining an elongate channelpositioned along a pivot axis; and a hinge member, associated with adeck panel, defining a flexible projection sized and shaped to besnapped into and retained within the pocket so as to allow pivotalmovement of the hinge member with respect to the support member aboutthe pivot axis.

According to another aspect of the invention, a support member for ahinge member defines one or two ledges for a deck panel associated withthe hinge member. One type of ledge is positioned to support the weightof the deck panel when stowed against a side wall of a compartment, andthe other type of ledge is positioned to support the weight of the deckpanel, and items loaded on it, when deployed away from the side wall.The ledges need not be smooth or planar or continuous; they shouldprovide sufficient points of support to receive the deck panel in astable fashion.

Generally described, according to this aspect the invention provides afreight compartment, comprising a compartment having a floor and atleast two spaced apart side walls; at least one support member,extending generally horizontally along one of the side walls; and atleast one hinge member, associated with a deck panel, engaging thesupport member so as to allow pivotal movement of the hinge member,along with the associated deck panel, between a generally upright stowedposition and a generally horizontal deployed position, about a pivotaxis; wherein the deck panel associated with the hinge member at leastpartially defines a platform in the compartment spaced above the floorwhen the deck panel is in the deployed position; and wherein the supportmember defines a first ledge, wherein the first ledge is positioned toengage the deck panel in a deployed configuration so as to substantiallyisolate the hinge member from weight of the deck panel and items on it.The support member optionally and preferably defines a second ledge,wherein the second ledge is positioned to bear weight of the deck panelwhen stowed generally upright against the side wall so as tosubstantially isolate the hinge member from the weight of the deckpanel.

According to another aspect of the invention, a hinge member is movablysupported by a deck panel so that the hinge member can move relative tothe deck panel when the deck panel is deployed, such movement having acomponent of motion perpendicular to the side wall of the compartment.When the side wall flexes, such as during transport, the hinge membermoves relative to the deck panel, in most cases preventing the force ofthe flexing side wall from snapping a hinge member out of the pocket inwhich it is engaged.

Generally described, according to this aspect the invention provides afreight compartment, comprising a compartment having a floor and atleast two spaced apart side walls at least one support member, extendinggenerally horizontally along one of the side walls; and at least onehinge member, associated with a deck panel, engaging the support memberso as to allow pivotal movement of the hinge member, and the associateddeck panel, between a generally upright stowed position and a generallyhorizontal deployed position; wherein the deck panel associated with thehinge member at least partially defines a platform in the compartmentspaced above the floor when the deck panel is in the deployed position;and wherein the hinge member is movably supported by the deck panel sothat the hinge member can move relative to the deck panel when the deckpanel is deployed, such movement having a component of motionperpendicular to the side wall. In one embodiment, the hinge memberincludes at least one block sized to be received in a cavity formed inan end of the deck panel. The block can move within the cavity, and isurged into the cavity. Optionally, a plurality of separate blocks andcavities may be provided for a deck panel.

One of various intermediate deck support systems with which the hingeand support system may be utilized includes at least one pair of deckpanels mounted opposite one another on the side walls, the deck panelsbeing capable of movement between an upright or stowed position and adeployed position. Each of the respective deck panels have an endpivotably mounted to the side wall and a free end. When the deck panelsare in the deployed position they at least partially define a secondaryplatform of the vehicle freight compartment when the free ends areadjacent to one another in the deployed position. The deck supportsystem also includes one or more anchors mounted to each of the sidewalls of the freight compartment to secure the deck panels to the sidewalls in the upright position.

In this embodiment, the system includes a support bracket that removablyengages the deck panels adjacent the free ends when the deck panels arein the deployed position. In one embodiment, the support bracketremovably engages the deck panels along a side edge of each panel. Thesupport bracket interlocks the pair of deployed deck panels and providesa support ledge for other deck panels. The bracket has an elongatedbody, which preferably has a rectangular cross section and defines alongitudinal axis. The elongated body has a first side and a second sidewith a longitudinally extending channel defined in the first side, whichis shaped for removable engagement with the pair of deck panels. Theelongated body also has a longitudinally extending support ledge definedin its second side. The longitudinally extending channel of the bracketinterlocks the deployed deck panels and the longitudinally extendingsupport ledge is capable of providing support to further pairs ofdeployed deck panels.

In one embodiment, the longitudinally extending channel slidably engagesthe deployed deck panels and is capable of linear movement perpendicularto the mating faces of the deployed deck panels. This arrangement mayfurther include a stop bracket affixed to one panel limiting the slidingmovement of the channel to facilitate optimal positioning of the channelrelative to the panels. In another embodiment, the first side of theelongated body of the bracket is pivotably secured to one of the deckpanels of the pair and the longitudinally extending channel pivotablyengages the deployed deck panels.

In a preferred embodiment, the deck support system also includes ahorizontal starter panel secured at the front of the freight compartmentbetween the side walls and adjacent at least one pair of the deployeddeck panels. In this embodiment, a support bracket is secured to thestarter panel to support a pair of deployed deck panels adjacent thestarter panel.

Advantageously, the deck support system of the present inventionsupports articles more efficiently than prior art systems fortransportation purposes. In particular, the deck support system islightweight and is of highly efficient design whereby the deck can beeconomically installed in a vehicle, each individual intermediate deckis adequately supported and can be locked together with other decks, andthe system can be efficiently operated by a single user.

Furthermore, the hinge aspect of the present invention can be applied inmany contexts other than those described herein. This aspect of theinvention provides a hinge structure, comprising a first member definingone or more pockets therein, the one or more pockets each defining anelongate channel positioned along a pivot axis; and a second memberdefining at least one flexible projection sized and shaped to be snappedinto and retained within one of the pockets so as to allow pivotalmovement of the first member with respect to the second member about thepivot axis. In alternative embodiments, the flexible projection is of aflexibility selected so that one person can force the flexibleprojection to be snapped into and pulled out of the pocket. Similarly,each elongate channel may include a part-circular cross section thatextends beyond 180 degrees so as to allow the pocket to trap theflexible projection when the flexible projection is forced to flex andsnap into the pocket, and the flexible projection may comprise anarcuate finger that lies along a portion of a circle.

In one embodiment of the hinge structure, the second member may comprisea plurality of the flexible projections connected to a base, and theflexible projections may comprise arcuate fingers that lie along aportion of a circle and are attached at one end to the base. In thiscase the arcuate fingers may include at least one arcuate finger havinga direction of curvature opposite from a direction of curvature of atleast one other arcuate finger. The one or more channels may each definean elongate opening through which the fingers extend, the opening beingsufficiently wide to allow the second member to rotate from a generallyhorizontal position to a generally upright position.

In another embodiment of the hinge structure, the second membercomprises a rigid projection further comprising a first piece largelycircular in cross section mating with a second piece comprising alocking plunger, such that when the two pieces are fully mated, theassembly provides a near complete circular cross section. The lockingplunger is held in a mated position by a locking screw or spring. Whenthe locking plunger is partially mated, the effective diameter at aspecific orientation is less than the inside diameter of the pocket andthe assembly can be inserted into the retaining pocket when positionedat a specific angle relative to the pocket. After insertion, the lockingplunger returns to a fully mated position automatically by spring actionor by adjusting the locking screw. After the locking plunger is fullymated, the effective diameter at the specific orientation increases andthe hinge assembly can then pivot freely. The hinge assembly cannot beremoved from the pocket except when positioned at the specific angularposition and the locking plunger is partially mated.

In an alternative embodiment, the locking plunger is omitted and thehinge structure comprises a rigid projection that is largely circular incross section. The hinge structure can be inserted and removed from thepocket only at a specific angular position, but without application ofany force or adjustment of locking screws.

BRIEF DESCRIPTION OF THE DRAWINGS

Some of the advantages of the present invention have been stated, otherswill appear as the description proceeds, when considered in conjunctionwith the accompanying drawings, which are not necessarily drawn toscale, in which:

FIG. 1 is a perspective view, partially cutaway, of the rearward portionof a truck trailer including an embodiment of the deck support system inaccordance with the present invention;

FIG. 2 is a perspective view of the interior forward portion of thetruck trailer shown in FIG. 1 including an embodiment of the decksupport system;

FIG. 3 is a perspective view of a support bracket of the deck supportsystem;

FIG. 4 is a side view of a support bracket slidably secured to a deckpanel;

FIG. 5 is a plan view of the secured support bracket of FIG. 4;

FIG. 6 is a plan view of a support bracket pivotably secured to a deckpanel;

FIG. 7 is a perspective view of the interior forward portion of thetruck trailer demonstrating a horizontal starter panel and a supportbracket of the deck support system;

FIG. 8 is a perspective view of the interior forward portion of thetruck trailer demonstrating placement of a deck panel of the decksupport system;

FIG. 9 is a perspective view of the interior forward portion of thetruck trailer demonstrating placement of a support bracket over the deckpanel shown in FIG. 8;

FIG. 10 is a perspective view of the interior forward portion of thetruck trailer demonstrating placement of a deck panel of the decksupport system; and

FIG. 11 is a perspective view of the interior forward portion of thetruck trailer demonstrating the deck support system of the presentinvention.

FIG. 12 is a pictorial view of a molded plastic deck panel unit.

FIG. 13 is an end pictorial view of a hinge and support system embodyingthe invention with the associated deck panel in the deployed position.

FIG. 14 is an end pictorial view of a hinge and support system embodyingthe invention with the associated deck panel in the stowed position.

FIG. 15 is an exploded end pictorial view of a hinge and support systemembodying the invention.

FIG. 16 is an end pictorial view of a hinge and support system embodyingthe invention showing the block of the hinge member positionedsymmetrically within the deck panel.

FIG. 17 is a pictorial view of a support member utilized in embodimentsof the present invention, mounted on a trailer wall.

FIG. 18 is a pictorial view of the hinge embodying a plurality offlexible fingers in alternating directions.

FIG. 19 is a cross sectional view of the hinge embodiment of theinvention employing a two piece assembly shown in a fully matedposition.

FIG. 20 is a cross sectional view of the hinge and support systemembodying the invention showing the two piece hinge assembly in apartially mated position during insertion in the support system.

FIG. 21 is a cross sectional view of the hinge embodying a single piecehinge assembly.

DETAILED DESCRIPTION OF THE INVENTION

The present invention will now be described more fully hereinafter withreference to the accompanying drawings, in which embodiments of theinvention are shown. The invention may, however, be embodied in manydifferent forms and should not be construed as limited to theembodiments set forth herein; rather, these embodiments are provided sothat this disclosure will be thorough and complete, and will fullyconvey the scope of the invention to those skilled in the art. Likenumbers refer to like elements throughout.

Referring to the accompanying drawings, FIGS. 1-11 illustrate a decksupport system, indicated generally at 10 in FIG. 1, installed on atruck trailer 12. The truck trailer 12 is enclosed by side walls 14, aroof 16 and a floor 18. While the illustrated embodiment and thefollowing description describe the deck support system of the presentinvention in conjunction with a truck trailer, the deck support systemneed not be used in conjunction with a truck trailer, but can instead beused in conjunction with various types of freight compartments includingtransport vehicles or devices such as railway cars, airplanes ortransport containers.

As best shown in FIG. 2, the deck support system 10 generally includesat least one pair of deck panels 20 and 21 mounted opposite one anotheron the side walls 14 of truck trailer 12. The pair of deck panels 20 and21 are mounted on the side walls 14 by one or more anchors mounted toeach of the side walls. In one embodiment, these anchors are horizontalrails 22 that generally run the length of truck trailer 12. The deckpanels 20 and 21 are maintained in their upright position by locks (notshown) provided on the walls 14 of the truck trailer 12. As shown inFIGS. 8 and 9, the deck panels 20 and 21 are fitted with notchedmounting brackets 23 that are designed to hook over horizontal rails 22.In this way, the deck panels 20 and 21 may rotate about horizontal rails22 between a stored upright position and an extended horizontal deployedposition, both as shown in FIG. 2. The deck panels 20 and 21 have freeends 20 a and 21 a, respectively. When the deck panels 20 and 21 aredeployed and their respective free ends 20 a and 21 a are adjacent, thedeck panels 20 and 21 at least partially define a platform in trucktrailer 12 above the floor 18.

The deck support system 10 also includes a support bracket 24 a, whichis preferably removably mounted between each pair of extended deckpanels 20 and 21 to both interlock the pairs of deck panels 20 and 21together and provide support to the pairs of deck panels 20 and 21. Asshown in FIG. 3, the interlocking support bracket 24 has an elongatedbody and preferably is of a rectangular cross section. The supportbracket 24 includes a first side 26 defining a longitudinally extendedchannel 28. The support bracket 24 also includes a second side 30defining a longitudinally extending support ledge 32.

In the embodiment shown in FIG. 3, the longitudinally extending channel28 has an upper lip 29 and a lower lip 31. The lips 29 and 31 preferablyextend the length of channel 28. As shown in FIGS. 4 and 5, thelongitudinally extending channel 28 of support bracket 24 preferablyengages the edge of deck panels 20 and 21 by virtue of the upper lip 29and the lower lip 31. The upper lip 29 and the lower lip 31 engage aseries of grooves in deck panels 20 and 21. In particular, the deckpanel 20 includes an upper groove 33 a and a lower groove 33 b, and thedeck panel 21 includes an upper groove 35 a and a lower groove 35 b. Inorder to removably and slidably engage the deck panels 20 and 21, theupper lip 29 of support bracket 24 a engages upper groove 33 a of panel20 and upper groove 35 a of panel 21. Similarly, the lower lip 31 ofsupport bracket 24 a engages lower groove 33 b of panel 20 and lowergroove 35 b of panel 21. As shown in FIG. 5, a stop in the form of astop bracket 24 b is affixed to the panel 20 and stops the slidingaction of the support bracket 24 a in an optimal position. The stopbracket 24 b preferably is formed with the same cross section as that ofthe support bracket 24 a. However, other embodiments of the stop includea nib or protrusion formed on the panel, a screw head protruding fromthe surface of the panel, or similar means for limiting the lineartravel of the support bracket 24 a. By engaging the deck panels 20 and21 in this way, the support bracket 24 a is capable of linear travelacross the faces of deck panels 20 and 21 when the deck panels aredeployed. At the same time, the longitudinally extending channel 28 ofthe support bracket 24 a interlocks the deployed deck panels 20 and 21and the longitudinally extending support ledge 32 provides support tofurther pairs of adjacent deployed deck panels 20′ and 21′ as shown inFIG. 11. The grooves 35 a, 35 b are at least as long as the supportbracket 24, so that the bracket 24 can be stored with the deck panel 21without protruding past its free end 21 a.

Referring to FIGS. 7 through 11, a secondary platform in truck trailer12 may be constructed using the above described embodiment of the decksupport system 10 by first securing a starter panel 36 to the horizontalrails 22 between the vertical walls 14 and against the forward part oftruck trailer 12 as shown in FIG. 7. Although in this embodiment thestarter panel 36 is secured against the forward part of the trucktrailer 12, one of ordinary skill in the art will understand thatstarter panel 36 may be installed at any location in the trailer 12where the user desires to start building a secondary platform within thetruck trailer 12. Preferably, starter panel 36 is a continuous shelfthat extends between the vertical walls 14.

A bracket 38 may next be secured to starter panel 36 so that supportledge 32 provides a way to support subsequent deployed deck panels 20and 21. The first bracket 38 is preferably rigidly secured to starterpanel 36, but alternatively may be slidably secured thereon such as by alip and groove design and positioned using a stop bracket. As shown inFIG. 8, after the bracket 38 is in place, the deck panel 21 is rotatedfrom its upright position against wall 14 to its deployed position,resting on the bracket 38. In the alternative, a simple flange may beattached to the forward trailer wall to support the first pair of deckpanels to provide the same function as support ledge 32.

Next, as shown in FIG. 9, a support bracket 24 is slid over the deckpanel 21 to prepare for the horizontal deployment of the deck panel 20on the opposite side wall of truck trailer 12. The support bracket 24may either stored somewhere on the trailer and be slid over the deckpanel 21 (as described) or may be included on the deck panel 21 whilethe deck panel 21 is in its upright position. It will be seen that inthe upright position of the panel 21, each bracket 24 assists in holdingthe next adjacent panel (towards the rear of the trailer) against thetrailer sidewall. This is also true of the preferred stop bracket withrespect to holding adjacent deck panels against the opposite side wall.As shown in FIG. 10, the support bracket 24 a is slid onto the deckpanel 21 out of the way of the deck panel 20, and then the deck panel 20is deployed to its horizontal position. The support bracket 24 a is thenslid back until it engages both deck panel 20 and deck panel 21. Thestop bracket 24 b ensures that the support bracket 24 a is slid back tothe proper position with roughly half the length of the support bracketon one panel 21′ and the other half on the other panel 20′. The supportbracket 24 a engages the deck panels 20 and 21 by virtue of theengagement of upper lip 29 and lower lip 31 on the support bracket 24 awith the upper groove 33 a and lower groove 33 b of deck panel 20, andthe upper groove 35 a and lower groove 35 b of deck panel 21.

As shown in FIG. 5, preferably the upper grooves 35 a, 35 b of deckpanel 21 are longer than upper grooves 33 a, 33 b of deck panel 20.Because of this, the support bracket 24 a can travel further onto deckpanel 21 and completely out of the way of the deck panel 20. On theother hand, when the support bracket 24 a engages the deck panel 20,preferably it may only travel far enough to provide complete engagementbetween the deck panel 20 and the deck panel 21. Proper positioning ofthe support bracket is facilitated by the stop bracket 24 b. Thus, afterthe deck panel 20 is deployed, the support bracket 24 a is slid backonto the deck panel 20 so that it slidably engages both deck panels 20and 21 and locks them together. This process is repeated, asdemonstrated in FIG. 11, until the desired number of deck panels areextended from their vertical position so that a sufficient amount ofsecondary platform space is created in truck trailer 12 for the storageof articles.

In another embodiment of the deck support system, shown in FIG. 6, thesupport bracket 24 does not include an upper lip 29 and lower lip 31 andthe deck panels 20 and 21 do not include a series of grooves. Instead,the support bracket 24 includes only a longitudinally extending channel28 and a longitudinally extending support ledge 32. In this embodiment,support bracket 24 is rotatably secured to one of the two deck panels 20and 21 of the pair. This may be done, for example, by a pivot pin 34secured through the first side 26 of support bracket 24. The supportbracket 24 can be rotated into position to interlock the deck panels 20and 21 when the deck panels 20 and 21 are deployed to the horizontalposition, thereby providing the interlocking and support for the deckpanels 20 and 21. Because the support bracket 24 is rotated intoposition, the stop bracket is not required in this embodiment to limitsliding movement of the support bracket. Nevertheless, a stop bracketmay be used to facilitate support of the next adjacent panels 19 in anupright position described above and as shown in FIG. 2.

In this embodiment, a secondary platform in truck trailer 12 may beconstructed using the deck support system 10 by first securing a starterpanel 36 to the horizontal rails 22 between the vertical walls 14 andagainst the forward part of truck trailer 12 as shown in FIG. 7. Again,preferably, starter panel 36 is a continuous shelf that extends betweenthe walls 14. A bracket 38 may next be secured to starter panel 36 sothat support ledge 32 provides a way to support subsequent deployed deckpanels 20 and 21. After the bracket 38 is in place, the deck panel 21 isrotated from its upright position against wall 14, with the supportbracket 24 pivotably secured to the panel 21, to its deployed position,resting on the bracket 38.

The support bracket 24 is rotated out of the way of the path of rotationof the deck panel 20 to prepare for the horizontal deployment of thedeck panel 20. The deck panel 20 is then deployed to its horizontalposition and the support bracket 24 is rotated into position, asdemonstrated in FIG. 6, so that it engages both the deck panel 20 andthe deck panel 21 and provides a support ledge for subsequently deployeddeck panels. Again, this process is repeated until the desired number ofdeck panels are extended from their vertical position so that asufficient amount of secondary floor space is created in truck trailer12 for the storage of articles.

FIGS. 12 through 15 show an alternative system for pivotally mountingdeck panels to the side walls 14 of the freight compartment. Analternative deck panel 50, which can be made of 30% glass filled nylon,or any other suitable plastic, metal, or composite material, is shown inFIG. 12. A light-weight molded synthetic deck panel in which the endsare capped may be preferred.

A hinge member 55 is mounted or formed along the end of the deck panel50 that is to be connected to the side wall 14. In a preferredembodiment, the hinge member includes one or more blocks 57 and aplurality of somewhat flexible fingers 60 and 61 spaced along each block57. A portion of a block 57 is shown in FIG. 18. Preferably, the fingers60 are arcuate, and may lie along a portion of a circle. The similarfingers 61 curve in the opposite direction to the fingers 60 and may bepositioned along the block 57 either even with or alternating with thefingers 60. If directly opposite one another, the length of therespective fingers should be such that they do not interfere with oneanother when flexing as described below.

The block 57 is sized to be received in a cavity 63 formed in the end ofthe panel 50. The interior surfaces of the cavity define a space withinwhich mating areas of the block can slide. The block 57 is pulled backagainst an interior wall or stop of the cavity 63 by a spring 65, orother elastic member, strong enough to hold the block firmly in thecavity during routine operation of the deck system between the stowedand deployed configurations. For example, if a single elongate block 57is used, two 20-30 pound springs, one near each end of the hinge, wouldbe suitable. Each spring may extend from a post 66 within the block 57,through an opening 67 in the block. The interior wall may have anopening (not shown) through which the spring extends to be secured to areinforced member 64 within the panel 50 shown in dashed lines in FIG.14.

The alternative system for pivotally mounting deck panels to the sidewalls 14 also includes a support member 75 which may be an aluminumextrusion or a formed, molded, or assembled part of any suitablematerial. The support member 75 as shown in FIGS. 12-16 defines avertical wall 77 adapted to be secured to the side wall 14 by anysuitable means. Another embodiment of the support member 75 is shownmounted on a side wall 14 in FIG. 17. In the embodiment of FIG. 17, thesupport member 75 has an open back portion and vertical wall portions 77a and 77 b which can engage the side wall at upper and lower extremes ofthe support member. A lower wall 78 angles upwardly to a horizontalledge 80. From the ledge 80, a vertical wall 84 extends up to a pocket86. A second ledge 82 is defined at the opposite side of the pocket 86,and extends to the vertical wall 77, or the portion 77 a in the case ofthe embodiment shown in FIG. 17. The width of the ledge 80 preferably isnot larger than the thickness of the deck panel 50, as shown in FIG. 14,so that the ledge does not protrude into the compartment any fartherthan the stowed deck panel. The ledge 80 bears the weight of thedeployed deck panel 50 as shown in FIG. 13, and the ledge 82 bears theweight of the deck panel 50 when stowed, as shown in FIG. 14. The ledgesprevent the hinge fingers 60 and 61 from bearing such weight.

The pocket 86 is shown as an elongate channel forming part of a circlein cross section. In a preferred embodiment, the partial circle of thepocket extends beyond 180 degrees to lips 88 and 89 of the pocket 86(marked in FIG. 14), allowing the pocket 86 to trap the arcuate fingers60 and 61 when they are forced to flex and snap into the pocket 86.Preferably, the deck panel 50 is sufficiently light in weight and thefingers 60 and 61 are of a flexibility selected so that one person canmanipulate a deck panel to a position in which the line of fingersaligns with the elongate pocket 86, and can force the fingers to snapinto the pocket (or remove the fingers from the pocket for disassembly).It should be understood, however, that the profile of the pocket neednot be part of a circle or form a smooth curve. Also, the fingers neednot be circular or arcuate, and alternatively each pair of fingers 60and 61 could be replaced by any compressible member or assembly capableof being forced into and retained movably within the pocket forfunctioning as a hinge.

Furthermore, it should be understood that two or more separate pocketscould be provided spaced along the end of the deck panel 50, with hingemembers on the panel at mating locations. In such a case the block couldbe an elongate structure, or separated blocks could be received inseparate cavities in the panel.

The support member 75 is shown in FIGS. 12-16 with internal reinforcingweb structures. These may not be needed depending on the weight of itemsbeing transported, and are not present in the embodiment shown in FIG.17. Also, the portion of the vertical wall 77 below the ledge 82 may beomitted.

In another embodiment shown in FIG. 16, a block 57′ may be positioned ina cavity formed symmetrically within a deck panel 50′. In thisembodiment, the fingers 60 and 61 are mounted asymmetrically to theblock, resulting in the deck panel, the fingers 60 and 61, and thesupport member 75 having the same relative orientation as shown in FIGS.13 and 14. The purpose for this alternative is to allow the deck panel50′ to be made in two symmetrical “clamshell” halves with half of thecavity 63 in each half of the deck panel.

From the foregoing, assembly and use of a deck panel supported accordingto the embodiment as shown in FIGS. 12-18 will be apparent to thoseskilled in the art. The hinge members 55 are placed within the portionof a cavity 63 formed in a half of a deck panel 50 or 50′, and a springis connected between the post 66 and the reinforced member 64. Then theother half of the deck member is engaged to complete the deck member andform the cavity 63 with the flexible fingers 60 and 61 protruding. Asupport member 75 is attached to a side wall 14 of a compartment,usually in a horizontal orientation. Given a preferred construction ofthe support member and the deck hinge member, one person can manipulatethe flexible fingers into alignment along the pocket or pockets 86 ofthe support member, and force the fingers to snap into the pocket. Theinstalled configuration is shown in FIGS. 13, 14, and 16. In use, thedeck panel now can be rotated about the hinge axis from a stowedconfiguration shown in FIG. 14 to a deployed configuration shown in FIG.13. The relative positioning, central support, and locking of aplurality of the deck panels 50 or 50′ within a freight compartment canbe done according to the systems described above in connection withFIGS. 1-11.

Another embodiment of the hinge member is illustrated in FIG. 19 wherethe hinge member includes an elongate, arcuate member 90 attached toeach block 57 at the same positions as fingers 60, 61 in an earlierembodiment. Preferably, the arcuate member 90 lies along a portion of acircle, defining a gap 96 at an angle from a perpendicular extendingfrom the face of the block 57. At the edges of the gap, inwardlydirected flanges are extruded to form a slot. A locking plunger 91 isprovided and shaped for sliding movement within the slot 95. An outersurface of the plunger 91 is curved at the same radius as the hinge 90.The hinge member 90 is preferably made from a rigid material, such asextruded aluminum or a plastic-based material.

The locking plunger in FIG. 19 is illustrated as fully mated, that is,fully extended outwards from the center of the circle formed by therigid circular member 90. In the fully mated position, the assembly ofthe circular member 90 and the locking plunger 91 form a largelycomplete circle that is designed to pivot inside the pocket 86 wheninserted. The diameter of the largely complete circle when measuredalong the path of the locking plunger 91 is illustrated as d₂. Thedistance d₂ varies based on the position of the plunger 91. The diameterof the largely completed circle not intersecting the gap 96 isillustrated as d₁ and does not vary with the position of the plunger 91.When the plunger is fully mated, the diameter of d₂ is equal to d₁. Thelocking plunger 91 is held in the mated position by one of a variety ofmethods. Illustrated in FIG. 19 is a spring 94 positioned between thecircular member 90 and the locking plunger 91 so that the springs pushesthe locking plunger against the circular member. The spring may bemaintained in its position in a conventional manner using nibs 92present on the locking plunger and on the inside surface of the acuatemember. Another embodiment for maintaining the locking plunger 91 in afully mated position is to use a set screw (not shown) extending intothe hinge member from approximately opposite the gap 96, to push thelocking plunger against the circular member.

In this embodiment, the locking plunger must be in a partially matedposition in order to insert the hinge into the pocket assembly asillustrated in FIG. 20. The pocket 86 forms a semi-circular structuregreater than 180 degrees and is bounded by the edges or lips of thepocket 93 a, 93 b The pocket opening is the distance between the lips 93a, 93 b and is less than the inside diameter of the pocket The outsidediameter d₁ formed by the circular member 90 is slightly smaller thanthe inside diameter of the pocket 86 but greater than the pocket openingsuch that insertion or removal of the hinge assembly is not possiblewhen the locking plunger 91 is fully mated or the hinge 90 is orientedwith the full diameter d₁ facing the opening of the pocket 86. Theillustration of FIG. 20 depicts the insertion of the hinge into thepocket with the locking plunger partially mated. In FIG. 20, theinsertion of the hinge requires the hinge and deck panel assembly to beat a certain angle so that the diameter d₂ of the hinge is presented andallowed to pass though the opening of the pocket As the hinge isinserted into the pocket, the pocket lip 93 a pushes against the lockingplunger 91 forcing it inward such that d₂ is less than d₁. The spring 94is compressible and the locking plunger maintains contact with thepocket lip 93 a while it compresses the spring 94. Because insertion orremoval requires compression of the spring, a measure of lateral forceis required for the hinge to be inserted. After the hinge is fullyinserted into the pocket, the spring forces the locking plunger backinto the fully mated position such that d₂ is equal to d₁, allowing thehinge to be rotated. When the deck plunger 57 is rotated to a horizontalposition (not shown), the hinge assembly is retained within the pocketbecause a full diameter d₁ is presented to the pocket opening. Thediameter d₁ is does not vary and is greater than the pocket opening. Ifa locking set screw is used to position the locking plunger, the screwcan be advanced after the hinge is inserted to mate the locking plungerfor smooth rotation of the hinge.

In another embodiment of the hinge structure, shown in FIG. 21, thehinge can comprise solely the partial circular rim of the hinge 90without any locking plunger and spring. This allows insertion andremoval of the hinge at a specific angle without any force. The specificangle is obtained when the diameter as defined by d₃ is opposite to theopening of the pocket (not shown). Once the hinge is fully inserted andis rotated to a horizontal or vertical position, the diameter of thehinge 90 as defined by d₁ is retained within the pocket by the lips 93a, 93 b of the pocket. In use of this embodiment, care should be takennot to exert a withdrawing force on the deck panel while it is beingrotated between its stowed and deployed positions.

Many modifications and other embodiments of the invention will come tomind to one skilled in the art to which this invention pertains havingthe benefit of the teachings presented in the foregoing descriptions andthe associated drawings. Therefore, it is to be understood that theinvention is not to be limited to the specific embodiments disclosed andthat modifications and other embodiments are intended to be includedwithin the scope of the appended claims. Although specific terms areemployed herein, they are used in a generic and descriptive sense onlyand not for the purposes of limitation.

1. A hinge structure, comprising: a rigid first member comprising aconcave receptacle portion, said concave receptacle portion defining anopen channel positioned along a pivot axis; and a second member definingat least one flexible projection sized and shaped to be snapped into andretained within said concave receptacle portion so as to allow pivotalmovement of said first member with respect to said second member aboutsaid pivot axis such that the at least one flexible projection isretained within said concave receptacle portion along the entire rangeof pivotal movement of said first member with respect to said secondmember.
 2. The hinge structure of claim 1 wherein the flexibleprojection comprises a semi-circular shaped cross section.
 3. The hingestructure of claim 1 wherein said flexible projection comprises aplurality of arcuate fingers.
 4. The hinge structure of claim 3 wheresaid arcuate fingers comprise at least one arcuate finger having adirection of curvature opposite from a direction of curvature of atleast one other arcuate finger.
 5. The hinge structure of claim 1,wherein said concave receptacle portion traps said flexible projectionwhen said flexible projection is forced to flex and snap into saidconcave receptacle portion.
 6. The hinge structure of claim 1, whereinsaid flexible projection is of a flexibility selected to allow theflexible projection to be snapped into and pulled out of said concavereceptacle portion.
 7. The hinge structure of claim 1, wherein saidflexible projection comprises an arcuate finger.
 8. The hinge structureof claim 1, wherein said second member comprises a plurality of saidflexible projections connected to a base.
 9. The hinge structure ofclaim 1 wherein said concave receptacle portion defines an opening thatis parallel to said pivot axis.
 10. The hinge structure of claim 9wherein said flexible projection is sized and shaped to be insertedthrough said opening of said concave receptacle portion so as to allowpivotal movement of said first member about said pivot axis such thatsaid at least one flexible projection is retained within said concavereceptacle along the entire range of pivotal movement of said firstmember with respect to said second member.
 11. The hinge structure ofclaim 1 wherein a cross-section of said concave receptacle portion isc-shaped.
 12. A hinge structure comprising: a rigid first membercomprising a concave receptacle portion, said concave receptacle portiondefining an open channel positioned along a pivot axis; and a secondmember defining at least one flexible projection sized and shaped to besnapped into and retained within said concave receptacle portion so asto allow pivotal movement of said first member with respect to saidsecond member about said pivot axis such that the at least one flexibleprojection is retained within said concave receptacle portion along theentire range of pivotal movement of said first member with respect tosaid second member, wherein said second member comprises a plurality ofsaid flexible projections connected to a base and said flexibleprojections comprise arcuate fingers that are attached at one end tosaid base.
 13. A hinge structure comprising: a rigid first membercomprising a concave receptacle portion, said concave receptacle portiondefining an open channel positioned along a pivot axis; and a secondmember defining at least one flexible projection sized and shaped to besnapped into and retained within said concave receptacle portion so asto allow pivotal movement of said first member with respect to saidsecond member about said pivot axis such that the at least one flexibleprojection is retained within said concave receptacle portion along theentire range of pivotal movement of said first member with respect tosaid second member, and said second member comprises a plurality of saidflexible projections connected to a base, wherein said flexibleprojections comprise arcuate fingers that are attached at one end tosaid base, and wherein said arcuate fingers attached to said basecomprise at least one arcuate finger having a direction of curvatureopposite from a direction of curvature of at least one other arcuatefinger.
 14. A hinge structure comprising: a first member defining one ormore pockets therein, said one or more pockets each defining an elongatechannel positioned along a first pivot axis, wherein said elongatechannel has a part-circular cross section that extends beyond 180degrees; and a second member defining at least one rigid projectionhaving a portion of a cross section corresponding to a semi-circularshape that is sized so as to be insertable into said pocket withoutdeforming said pocket of said first member when positioned at a firstrelative angle to the first member, said projection retained within saidpocket when pivoted along the pivot axis to a second relative angle tothe first member wherein the second member comprises a locking plungerdisposed relative to said rigid projection, said locking plunger havinga cross section of a second semi-circular shape and positioned so as toresult in the second member snapping into the first member when insertedinto said pocket.
 15. A hinge structure comprising: a first memberdefining one or more pockets therein, said one or more pockets eachdefining an elongate channel positioned along a first pivot axis,wherein said elongate channel has a part-circular cross section thatextends beyond 180 degrees; and a second member defining at least onerigid projection having a portion of a cross section corresponding to asemi-circular shape that is sized so as to be insertable into saidpocket without deforming said pocket of said first member whenpositioned at a first relative angle to the first member, saidprojection retained within said pocket when pivoted along the pivot axisto a second relative angle to the first member wherein the second membercomprises a locking plunger disposed relative to said rigid projection,said locking plunger having a cross section of a second semi-circularshape and positioned so as to result in the second member snapping intothe first member when inserted into said pocket; wherein said lockingplunger mates with the rigid projection by use of a spring.
 16. A hingestructure, comprising: a first member comprising a concave receptacleportion, said concave receptacle portion defining an open channelpositioned along a pivot axis, wherein said open channel has apart-circular cross section that extends beyond 180 degrees; and asecond member defining a uniform projection sized and shaped to beinserted into and retained within said concave receptacle portion so asto allow pivotal movement of said first member with respect to saidsecond member about said pivot axis such that the projection is retainedwithin said concave receptacle portion along the entire range of pivotalmovement of said first member with respect to said second member,wherein the uniform projection is flexible so that said projection snapsinto said concave receptacle portion of said first member when inserted.17. The hinge structure of claim 16 wherein the uniform projection ismade of plastic.
 18. A hinge structure, comprising: a first membercomprising a concave receptacle portion, said concave receptacle portiondefining an open channel positioned along a pivot axis, wherein saidopen channel has a part-circular cross section that extends beyond 180degrees; and a second member defining a uniform projection sized andshaped to be inserted into and retained within said concave receptacleportion so as to allow pivotal movement of said first member withrespect to said second member about said pivot axis such that theprojection is retained within said concave receptacle portion along theentire range of pivotal movement of said first member with respect tosaid second member, wherein the uniform projection snaps into theconcave receptacle portion when inserted.